1. Manuals
  2. Brands
  3. Mercury Manuals
  4. Engine
  5. 2.8 EI 200
  6. Manual

Mercury 2.8 EI 200 Manual

Diesel inboard models
Hide thumbs
Table of Contents

Advertisement

Quick Links

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 2.8 EI 200 and is the answer not in the manual?

Questions and answers

Related Manuals for Mercury 2.8 EI 200

Summary of Contents for Mercury 2.8 EI 200

  • Page 2 Precision Parts, Mercury Propellers, Marathon, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Pro Max, OptiMax, Sport–Jet, Cleaver, K–Planes, MerCathode, Quickleen, RideGuide, SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered service mark of Brunswick Corporation.
  • Page 3 0002.1 and CE459 WELCOME! You have selected one of the finest marine power packages available. It incorporates numerous design features to assure operating ease and durability. With proper care and maintenance, you will thoroughly enjoy using this product for many boating seasons.

  • Page 4: Read This Manual Thoroughly

    0004 Read This Manual Thoroughly IF YOU DON’T UNDERSTAND ANY PORTION, CONTACT YOUR DEALER FOR A DEMONSTRATION OF ACTUAL STARTING AND OPERATING PROCEDURES. NOTICE Throughout this publication, and on your power package, WARNINGS and CAUTIONS, accompanied by the International Hazard Symbol , may be used to alert the installer/user to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly.

  • Page 5: Table Of Contents

    SECTION 1 - WARRANTY Warranty Information ....What Cummins Mercruiser Diesel Will Owner Warranty Registration ... . .
  • Page 6 ....Conditions Affecting Operation ..Operation Chart - 2.8 EI 200 ... Weight Distribution (Passengers And...
  • Page 7 SECTION 5 - MAINTENANCE Owner/Operator Responsibilities ..Fuel System ..... . . Dealer Responsibilities ....Priming .
  • Page 8 SECTION 6 - STORAGE AND RECOMMISSIONING Cold Weather (Freezing Temperature), Seasonal Storage Instructions ..Seasonal, And Extended Storage ..Extended Storage Instructions ..Cold Weather (Freezing Temperature) Recommissioning .

  • Page 9: Section 1 Section

    WARRANTY SECTION 1 SECTION 1 SECTION 1 - WARRANTY Table of Contents Warranty Information ....What Cummins Mercruiser Diesel Will Owner Warranty Registration .

  • Page 10: Warranty Information

    • You may change your address at any time, including at time of warranty claim, by calling Mercury MerCruiser or sending a letter or fax with you name, old address, new address, and engine serial number to Mercury MerCruiser’s warranty registration department.

  • Page 11: International Owner Registration

    WARRANTY SECTION 1 SECTION 1 International Owner Registration OUTSIDE THE UNITED STATES AND CANADA • It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the distributor or Marine Power Service Center responsible for administering the warranty registration/claim program for your area.

  • Page 12: Warranty Policies

    Cummins MerCruiser Diesel’s sole and exclusive obligation under this warranty is limited to, at our option, repairing a defective part, replacing such part or parts with new or Mercury Marine certified re-manufactured parts, or refunding the purchase price of the Cummins MerCruiser Diesel product.

  • Page 13: How To Obtain Warranty Coverage

    WARRANTY SECTION 1 SECTION 1 HOW TO OBTAIN WARRANTY COVERAGE The customer must provide Cummins MerCruiser Diesel with a reasonable opportunity to repair, and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Cummins MerCruiser Diesel dealer / distributor authorized to service the product.

  • Page 14: Warranty Coverage And Exclusion

    WARRANTY SECTION 1 CE552 Warranty Coverage and Exclusion Keep in mind that warranty covers repairs that are needed within the warranty period because of defects in material and workmanship. Installation errors, accidents, normal wear, and a variety of other causes that affect the product are not covered. Warranty is limited to defects in material or workmanship, but only when the consumer sale is made in the country to which distribution is authorized by us.

  • Page 15: Package

    WARRANTY SECTION 1 SECTION 1 • Use of other than Quicksilver replacement parts when making warranty repairs. • Oils, lubricants or fluids changed as a matter of normal maintenance is customer’s responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration.

  • Page 16: Transferable Warranty

    Owner Warranty Registration Card and a copy of the bill of sale to show proof of ownership. In the United States and Canada, mail to: Mercury Marine Attn: Warranty Registration Department W6250 Pioneer Road P.O.

  • Page 17: Section 2 - Getting To Know Your Power

    GETTING TO KNOW YOUR POWER PACKAGE SECTION 2 SECTION 2 - GETTING TO KNOW YOUR POWER PACKAGE Table of Contents Features And Controls ....Audio Warning System .

  • Page 18: Section 2 - Getting To Know Your Power Package

    GETTING TO KNOW YOUR POWER PACKAGE SECTION 2 0010 Features And Controls 0011 Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves outside the operator’s position (as in accidental ejection from the operator’s position). 74608 Stop switch Lanyard...

  • Page 19: Package

    GETTING TO KNOW YOUR POWER PACKAGE SECTION 2 Activation of the lanyard stop switch will stop the engine immediately, but the boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut down. However, the boat will not complete a full circle. While the boat is coasting, it can cause injury to anyone in the boat’s path as seriously as the boat would when under power.

  • Page 20: Instrumentation

    GETTING TO KNOW YOUR POWER PACKAGE SECTION 2 00000 was 0012.2 Instrumentation INSTRUMENTS The following is a brief explanation of instrumentation typically found on some boats. The owner/operator should be familiar with all instruments and their functions on the boat. Because of the large variety of instrumentation and manufacturers, you should have your boat dealer explain the particular gauges and normal readings that will appear on your style gauges.

  • Page 21: Package

    GETTING TO KNOW YOUR POWER PACKAGE SECTION 2 a modified CD934 and CD860 SWITCHES 73547 79996 71891 70522 Typical switches Key switch Panel lights / audio test switch Bilge blower switch Key Switch - has three positions. 1. OFF - In the OFF position, all electrical circuits are off and engine cannot be started. The engine is stopped when the key switch is turned to the OFF position.

  • Page 22: Package

    GETTING TO KNOW YOUR POWER PACKAGE SECTION 2 CE479 and CD860 ENGINE MONITORING FEATURES 77359 Typical Malfunction indicator lamp Water-in-fuel warning lamp, if equipped Coolant temperature warning lamp Oil pressure warning lamp Charge indicator lamp Preheat indicator lamp The appropriate lamp functions as follows: Malfunction Indicator Lamp (MIL) - additional lamp indicates when a problem exists, or a malfunction has occurred, that requires service.

  • Page 23: Remote Controls

    SECTION 2 0014 Remote Controls Your boat may be equipped with a Mercury Precision Parts or Quicksilver remote controls. All controls may not have all features shown. Consult your dealer for a description and/or demonstration of your remote control. 0015.03...

  • Page 24: Console Mounted

    GETTING TO KNOW YOUR POWER PACKAGE SECTION 2 0242.01 CONSOLE MOUNTED 79770 79769 Throttle only button Control handles Throttle Only Button - Allows engine throttle advancement without shifting the engine. This is done by disengaging the shift mechanism from the control handle. The throttle only button can be depressed only when the remote control handle is in the NEUTRAL position, and should only be used to assist in starting the engine.

  • Page 25: Electrical System Overload Protection

    GETTING TO KNOW YOUR POWER PACKAGE SECTION 2 00000 was 0018.01 w / CMD change Electrical System Overload Protection If an electrical overload occurs, a fuse will blow or the circuit breaker will trip open. The cause must be found and corrected before replacing the fuse or resetting the circuit breaker. NOTE: In an emergency, when the engine must be operated and the cause for the high current draw cannot be located and corrected, turn OFF or disconnect all accessories connected to the engine and instrumentation wiring.

  • Page 26: Audio Warning System

    GETTING TO KNOW YOUR POWER PACKAGE SECTION 2 CE480 Audio Warning System Your Cummins MerCruiser Diesel power package may be equipped with an Audio Warning System. The Audio Warning System will not protect the engine or transmission from damage. It is designed to warn the operator that a problem has occurred. The audio warning system will sound with a continuous alarm if one of the following occurs: •...

  • Page 27: Emissions Information

    GETTING TO KNOW YOUR POWER PACKAGE SECTION 2 00000 was 0220.0 Emissions Information Exhaust Gas Emissions Certificate (Europe Only) A tamper-resistant label is affixed to the engine at time of manufacture by Cummins MerCruiser Diesel. In addition to the required exhaust gas emissions certificate number, the label lists the engine serial number, engine family, maximum rpm, engine power, and weight.
  • Page 28 GETTING TO KNOW YOUR POWER PACKAGE SECTION 2 NOTES: Page 20 CMD-4081877 / 90-865861040 MARCH 2004...

  • Page 29: Table Of Contents

    ....Conditions Affecting Operation ..Operation Chart - 2.8 EI 200 ... Weight Distribution (Passengers And...

  • Page 30: Safe Boating Suggestions

    ON THE WATER SECTION 3 00000 was 0022 w / CMD changes orCE554 Safe Boating Suggestions In order to safely enjoy the waterways, familiarize yourself with local and all other governmental boating regulations and restrictions and also consider the following suggestions.
  • Page 31 ON THE WATER SECTION 3 • Watch for signs of weather change and avoid foul weather and rough-sea boating. • Tell someone where you are going and when you expect to return. • Passenger boarding. Stop the engine whenever passengers are boarding, unloading or are near the back (stern) of the boat.

  • Page 32: Be Alert To Carbon Monoxide Poisoning

    ON THE WATER SECTION 3 • Know your boating area and avoid hazardous locations. • Be alert. The operator of the boat is responsible by law to “maintain a proper lookout by sight and hearing.” The operator must have an unobstructed view particularly to the front.

  • Page 33: Good Ventilation

    ON THE WATER SECTION 3 0024.01 GOOD VENTILATION Ventilate the passenger area by opening the side curtains or forward hatches to remove fumes. mc79553 Courtesy of ABYC Example of desired air flow through the boat 0025.01 POOR VENTILATION Under certain conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide.

  • Page 34: Basic Boat Operation

    ON THE WATER SECTION 3 0026 Basic Boat Operation 0027.1 Launching And Boat Operation Care CAUTION To avoid possible ingestion of water that can damage engine components: • Do not turn the ignition key off when the engine is above idle speed. w When launching your boat from a steep ramp, enter the water slowly.

  • Page 35: Duty Cycle Rating

    ON THE WATER SECTION 3 CD908 CE465 or similar to Duty Cycle Rating IMPORTANT: Damage caused by improper application or failure to operate the power package within the specified operating parameters, will not be covered by the Cummins MerCruiser Diesel Limited Warranty. It is the responsibility of the boat manufacturer and/or the installing dealer to ensure that the power package is properly applied.

  • Page 36: Operation Chart - 2.8 Ei 200

    ON THE WATER SECTION 3 00000 was CD864 with header change Operation Chart - 2.8 EI 200 STARTING AFTER WHILE STOPPING & PROCEDURE STARTING UNDERWAY SHUT DOWN Observe all gauges and Frequently observe all Shift remote control Open engine hatch. Air...

  • Page 37: Starting, Shifting And Stopping - 2.8 Ei 200

    ON THE WATER SECTION 3 00000 was CD863 with changes to Engine Oil bullet point Starting, Shifting and Stopping - 2.8 EI 200 WARNING Do not use volatile starting aids, such as Ether, Propane, or Gasoline in the engine air intake system. Explosion hazard resulting from ignition of vapors by glow plugs could cause severe personal injury and engine damage.

  • Page 38: Starting A Cold Engine

    ON THE WATER SECTION 3 00000 was CE298 w changes in all with revision bars STARTING A COLD ENGINE IMPORTANT: Always check fluid levels before starting the engine. Refer to Maintenance Chart. 1. Turn on and run engine compartment bilge blower (if so equipped) for five minutes. Or, open engine hatch to air out bilge before attempting to start engine.

  • Page 39: Engine Shut-Down (Stopping)

    ON THE WATER SECTION 3 CE526 STARTING A WARM ENGINE 1. Place control handle in NEUTRAL. 2. Turn key switch to the RUN position. 3. Turn key switch to START position and release when engine starts. Ensure charge indicator and oil pressure warning lamps go off. 4.

  • Page 40: Freezing Temperature And Cold Weather Operation

    ON THE WATER SECTION 3 CE468 Freezing Temperature And Cold Weather Operation IMPORTANT: If boat is operated during periods of freezing temperature, precautions must be taken to prevent freezing damage to power package. Damage caused by freezing IS NOT covered by Cummins MerCruiser Diesel Limited Warranty. CAUTION Seawater (raw water) section of cooling system MUST BE COMPLETELY drained for winter storage or immediately after cold weather use, if the possibility of freezing...

  • Page 41: Protecting People In The Water

    ON THE WATER SECTION 3 0032 Protecting People In The Water While You Are Cruising It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his/her direction even at slow speed. Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water.

  • Page 42: Passenger Safety Message - Pontoon And Deck Boats

    ON THE WATER SECTION 3 0131.02 Passenger Safety Message - Pontoon And Deck Boats WARNING Avoid serious injury or death from falling over the front end of a pontoon or deck boat and coming in contact with the boat hull or propeller. Stay back from the front end of the deck and remain seated while the boat is in motion.

  • Page 43: Wave And Wake Jumping

    ON THE WATER SECTION 3 0034.01 Wave And Wake Jumping mc79675 WARNING Avoid serious injury or death from being thrown within or out of a boat when it lands after jumping a wave or wake. Avoid wave or wake jumping whenever possible. Instruct all occupants that if a wake or wave jump occurs, get low and hang on to a boat hand hold.

  • Page 44: Impact With Underwater Hazards

    ON THE WATER SECTION 3 0035.02 Impact With Underwater Hazards mc79680 Reduce speed and proceed with caution whenever you’re driving a boat in shallow water areas or in areas where the waters are suspected of having underwater obstacles that could be struck by the underwater drive components, rudder or the boat bottom.

  • Page 45: Conditions Affecting Operation

    ON THE WATER SECTION 3 0036 Conditions Affecting Operation Weight Distribution (Passengers And Gear) Inside The Boat Shifting weight to rear (stern): • Generally increases speed and engine rpm • Causes bow to bounce in choppy water • Increases danger of following wave splashing into the boat when coming off plane •...

  • Page 46: Propeller Selection

    ON THE WATER SECTION 3 00000 was 0040 or CE464 w rev bar indicated changes Propeller Selection CAUTION The installed propeller must allow the engine to run at the Rated Engine rpm at WOT to avoid engine damage. Using a propeller that causes the engine to operate below the Rated Engine rpm can cause piston and/or valve damage (even if the engine is not operated at WOT).

  • Page 47: Getting Started

    ON THE WATER SECTION 3 0042 Getting Started 00000 was CD912 or CE555 with different rpms in lists Initial Break-In Procedure It is especially important that the following procedure be used on new diesel engines. This break-in procedure allows the proper seating of the pistons and rings, which greatly reduces the likelihood of problems.

  • Page 48: After Break-In Period

    ON THE WATER SECTION 3 0043 w / changes – CMD and remove last bullet, see CE475 After Break-In Period To help extend the life of your Cummins MerCruiser Diesel power package, the following recommendations should be considered: • Use a propeller that allows the engine to operate at the Rated Engine rpm at WOT when at full throttle with a full boat load.

  • Page 49: Section 4 - Specifications

    ... . . 2.8 EI 200 ......

  • Page 50: Fuel Requirements

    SPECIFICATIONS SECTION 4 CD164 Fuel Requirements WARNING Electrical system components on this engine are not external ignition protected. DO NOT STORE OR UTILIZE GASOLINE ON BOATS EQUIPPED WITH THESE ENGINES, UNLESS PROVISIONS HAVE BEEN MADE TO EXCLUDE GASOLINE VAPORS FROM ENGINE COMPARTMENT (REF: 33 CFR). Failure to comply could result in fire, explosion and/or severe personal injury.

  • Page 51: Diesel Fuel In Cold Weather

    SPECIFICATIONS SECTION 4 00000 was CE16 Diesel Fuel In Cold Weather Unaltered diesel fuels thicken and gel in cold temperatures, unless treated. Virtually all diesel fuels are climatized to allow their use in the particular region for that time of the year. If it becomes necessary to further treat diesel fuel, it is the owner/operator’s responsibility to add a commercial standard brand anti-gel diesel fuel additive, following that product’s directions.
  • Page 52 SPECIFICATIONS SECTION 4 The closed cooling section should be kept filled year-round with an acceptable antifreeze/coolant solution. Do not drain closed cooled section for storage, as this will promote rusting of internal surfaces. If engine will be exposed to freezing temperatures, ensure that the closed cooled section is filled with a properly mixed antifreeze/coolant solution, to protect engine and closed cooling system to lowest temperature to which they will be exposed.

  • Page 53: Engine Oil

    Engine crankcase Engine crankcase Obtain Locally Obtain Locally Wintershall Multi-Rekord Veedol Turbostar Wintershall VIiva 1 These oils are approved by Mercury Marine and Marine Power Europe. For all temperature operation use 15W-40 oil. CMD-4081877 / 90-865861040 MARCH 2004 Page 45...

  • Page 54: Engine Specifications

    SPECIFICATIONS SECTION 4 00000 was CD731 Engine Specifications 2.8 EI 200 Specification - Inboard Description Description 2.8 EI 200 Engine Type In-Line 4 Cylinder Diesel Displacement 2.8 liters ( 169 cu. in. ) Firing Order 1 - 3 - 4 - 2 Bore 94.1 mm ( 3.705 in.

  • Page 55: Fluid Specifications

    SPECIFICATIONS SECTION 4 0051.02 Fluid Specifications IMPORTANT: All capacities are approximate fluid measures. 00000 was CE487 CD868 information but in table like in gas and new CMD information ENGINE IMPORTANT: It may be necessary to adjust oil levels depending on installation angle and cooling systems (heat exchanger and fluid lines).

  • Page 56: Cmd-4081877 / 90-865861040 March

    SPECIFICATIONS SECTION 4 NOTES: Page 48 CMD-4081877 / 90-865861040 MARCH 2004...

  • Page 57: Table Of Contents

    SECTION 5 MAINTENANCE SECTION 5 - MAINTENANCE Table of Contents Owner/Operator Responsibilities ..Fuel System ......Dealer Responsibilities .

  • Page 58: Owner/Operator Responsibilities

    MAINTENANCE SECTION 5 CE466 Owner/Operator Responsibilities It is the operator’s responsibility to perform all safety checks, to ensure that all lubrication and maintenance instructions are complied with for safe operation and to return the unit to an authorized Cummins MerCruiser Diesel for a periodic checkup. Normal maintenance service and replacement parts are the responsibility of the owner/operator and as such, are not considered defects in workmanship or material within the terms of the warranty.

  • Page 59: Maintenance

    Before attempting maintenance or repair procedures not covered in this manual, it is recommended that the appropriate Cummins MerCruiser Diesel or Mercury MerCruiser Service Manual be purchased and read thoroughly. NOTE: Maintenance points are color coded for ease of identification. See the decal on engine for identification.

  • Page 60: Do-It-Yourself Maintenance Suggestions

    MAINTENANCE SECTION 5 CE473 Do-It-Yourself Maintenance Suggestions Present-day marine equipment, such as your Cummins MerCruiser Diesel power package, are highly technical pieces of machinery. Special fuel delivery systems provide greater fuel economies, but also are more complex for the untrained mechanic. If you are one of those persons who likes to do-it-yourself, here are some suggestions for you.

  • Page 61: Maintenance Schedules

    SECTION 5 MAINTENANCE 00000 was CD937 with deletions, and with added from CE511 Maintenance Schedules Routine Maintenance * Each Each Every Weekly Start Months Check the engine oil level (interval can be extended based on experience). Check the coolant level. If operating in salt, brackish or polluted waters, flush the cooling system after each use.

  • Page 62: Scheduled Maintenance

    MAINTENANCE SECTION 5 Maintenance Schedules (Continued) Scheduled Maintenance * Every After First hours or Annually Annually hours Change the engine oil and filter. Touch-up paint the power package and spray with corrosion guard. Change the transmission fluid. Replace the fuel filter(s). Check the steering system and the remote control for loose, missing or damaged parts.

  • Page 63: Maintenance Record

    SECTION 5 MAINTENANCE Maintenance Schedules (Continued) Scheduled Maintenance * (Continued) Every Every 1000 Every hours hours or 5 or 5 years years years Replace the coolant. Clean the aftercooler core. Clean the fuel tank. Check engine to propeller shaft alignment. Only perform maintenance which applies to your particular power package.
  • Page 64 MAINTENANCE SECTION 5 0166 Maintenance Record (continued) Hour Meter Maintenance Date Serviced By Reading Performed Page 56 CMD-4081877 / 90-865861040 MARCH 2004...

  • Page 65: Engine Oil

    SECTION 5 MAINTENANCE 0062 Engine Oil CAUTION ENVIRONMENTAL HAZARD! Discharge of oil or oil waste into the environment is restricted by law. Do NOT spill oil or oil waste into the environment when using or servicing your boat. Contain and dispose of oil or oil waste as defined by local authorities.

  • Page 66: Filling

    MAINTENANCE SECTION 5 00000 wasCD917 with remove other engines, add 2.8 200 Filling IMPORTANT: Do not overfill the engine with oil. 1. Remove the oil filler cap. 79911 Shown without engine cover Oil filler cap 2. Add specified oil to bring the level up to, but not over, the maximum mark on the dipstick. Capacity 2.8 ES 200 Fluid Type...

  • Page 67: Changing Oil And Filter

    SECTION 5 MAINTENANCE 0065 Changing Oil and Filter Refer to the Maintenance schedule for the change interval. Engine oil should be changed before placing the boat in storage. IMPORTANT: Change engine oil when the engine is warm from operation. Warm oil flows more freely, carrying away more impurities.
  • Page 68 MAINTENANCE SECTION 5 8. Use an appropriate socket to loosen the oil filter top piece. 9. Remove the top piece and cartridge type oil filter. 10. Disconnect and discard the old filter element. Discard the old O-ring from the top piece. 79929 79912 Top piece...

  • Page 69: Transmission Fluid

    SECTION 5 MAINTENANCE CE493 Transmission Fluid Checking 1. Remove the dipstick. IMPORTANT: When checking the fluid level, rest the dipstick on top of the threaded housing hole. Do not screw the dipstick into the threaded housing hole. 2. Check the fluid level as indicated on the dipstick with the dipstick resting on the top of the threaded hole.

  • Page 70: Filling

    MAINTENANCE SECTION 5 CE463 Filling 1. If necessary, add specified automatic transmission fluid through the dipstick threaded hole to bring the level up to the maximum mark on the dipstick. IMPORTANT: Use only specified Automatic Transmission Fluid (ATF). Í Í Í Í Í 79465 Dipstick Threaded hole...

  • Page 71: Changing

    SECTION 5 MAINTENANCE CE496 Changing 1. Clean the exterior of the transmission around the fluid filter assembly. 2. Use a 6 mm allen wrench and remove the fluid filter assembly by turning the assembly nut counterclockwise and pulling at the same time. 79799 Fluid filter assembly Assembly nut...
  • Page 72 MAINTENANCE SECTION 5 5. Remove and discard the filter element and the O-rings. 6. Coat the new O-rings with transmission fluid. 7. Install the new O-rings and filter element. 50975 27662 Filter element Cover O-rings CAUTION Transmission fluid filter assembly must be properly seated to avoid fluid foaming and/or loss of fluid resulting in decreased efficiency and/or damage to transmission.

  • Page 73: Engine Coolant

    SECTION 5 MAINTENANCE 0071.2 Engine Coolant CD166 / CD918 Checking CAUTION Avoid serious injury from burns. Do not remove coolant cap when engine is hot. Coolant may discharge violently. IMPORTANT: Check engine coolant BEFORE starting the engine. 1. Allow the engine to cool. 2.
  • Page 74 MAINTENANCE SECTION 5 5. With the engine at normal operating temperature, check the coolant level in the coolant expansion tank. Turn the pressure cap 1/4 turn to allow any pressure to escape slowly, then remove the cap. 6. The coolant level should be within 25 mm (1 in.) of the bottom of the filler neck or between the upper and lower marks, if marked.

  • Page 75: Filling

    SECTION 5 MAINTENANCE 00000 was 0072 / and CD166 Filling 1. If coolant is low in the coolant expansion tank, add specified coolant as necessary to bring the level to within 25 mm (1 in.) of the bottom of the filler neck or between the upper and lower marks, if marked.

  • Page 76: Air Filter

    MAINTENANCE SECTION 5 00000 was CD648 Air Filter Cleaning 1. Remove the nut, hardware and bracket, if equipped, attached to the air cleaner. 2. Carefully remove the air cleaner foam element from around the air intake screen housing mounted on the turbocharger inlet. 80012 79950 Sterndrive engine, Inboard similar...

  • Page 77: Water Separating Fuel Filter

    SECTION 5 MAINTENANCE 00000 was CD884 with CMD changes and additions Water Separating Fuel Filter WARNING Be careful when draining water separating fuel filter. Diesel fuel is flammable. Be sure ignition key is OFF. Do not allow fuel to contact any hot surfaces which may cause it to ignite.

  • Page 78: Draining

    MAINTENANCE SECTION 5 Draining The engine mounted water separating fuel filter can be drained of water and small dirt particles by opening drain cap on bottom of filter. NOTE: To ensure complete draining, in warm weather drain the filter before starting daily operations.

  • Page 79: Replacing

    SECTION 5 MAINTENANCE 00000 was CD885 with step 1 f added, 2 E and CMD changes Replacing 1. Unplug the WIF sensor wire from the drain cap. 80013 Typical Drain cap WIF sensor wire 2. Twist locking ring by hand. Remove water separating fuel filter and sealing ring from mounting bracket.
  • Page 80 MAINTENANCE SECTION 5 5. Lubricate the sealing ring on the new filter. 74731 Typical Drain cap O-ring Sealing ring Description Where Used Part Number Water separating fuel filter SAE 30W Engine Oil Obtain locally sealing ring 6. Align filter to bracket. Twist locking ring by hand to secure filter to bracket. Do not use a filter wrench.

  • Page 81: Filling

    SECTION 5 MAINTENANCE 00000 was CD882 using subsub only from mod Filling NOTE: Follow this procedure after installing new filter or if fuel has been drained from filter checking for water. 1. Loosen the bleed screw on fuel filter bracket. 80015 80015 Typical...

  • Page 82: Fuel System

    MAINTENANCE SECTION 5 00000 was CE406 removed some subsubs to make usable here Fuel System 00000 was CD881 Priming Prime engine if it has not been run for a while or if engine will not start. Move the hand pump/primer plunger up and down several times as previously outlined. Attempt to start engine.

  • Page 83: Lubrication

    SECTION 5 MAINTENANCE 0078 Lubrication Shift Cable 1. Lubricate the pivot points and the guide contact surfaces. 71374 Typical Pivot points Guide contact surfaces Description Where Used Part Number Pivot points, guide contact Engine Oil Obtain Locally surfaces 00000 was 0079 with diesel graphics added Throttle Cable 1.

  • Page 84: Drive Belts

    MAINTENANCE SECTION 5 0000000 was CD794 – minor text changes to align with latest effort at translations – CMD changes Drive Belts All drive belts must be periodically inspected for tension and condition (excessive wear, cracks, fraying, or glazed surfaces). If any drive belts need replacement or tension needs adjustment, see your authorized Cummins MerCruiser Diesel dealer / distributor.
  • Page 85 SECTION 5 MAINTENANCE 2. Inspect serpentine belt for proper tension and for the following: • Excessive wear • Cracks NOTE: Minor, transverse cracks (across the belt width) may be acceptable. Longitudinal cracks (in direction of belt length) that join transverse cracks are NOT acceptable. •...

  • Page 86: Corrosion Protection

    MAINTENANCE SECTION 5 0161.02 Corrosion Protection Whenever two or more dissimilar metals are submerged in a conductive solution, such as saltwater, polluted water or water with a high mineral content, a chemical reaction takes place causing electrical current to flow between metals. The electrical current flow causes the metal that is most chemically active, or anodic, to erode.

  • Page 87: Inspection

    SECTION 5 MAINTENANCE INSPECTION NOTE: Remove deposits from surface of anode before trying to determine amount of erosion. 1. Replace anode assembly when deteriorated 50%. • Length When New - 19 mm (3/4 in.) Diameter When New - 16 mm (5/8 in.) •...

  • Page 88: Installation

    MAINTENANCE SECTION 5 INSTALLATION 1. Install new sealing washer. 2. Install anode plug, with sacrificial anode and washer into heat exchanger or aftercooler end cover. Tighten securely. 71368 Plug And Anode Sealing Washer CAUTION Avoid seawater pump impeller damage. Do not operate the engine without cooling water being supplied to the seawater pickup pump.
  • Page 89 SECTION 5 MAINTENANCE CAUTION Avoid damage to heat exchanger and subsequent possible engine damage. Remove all water from heat exchanger sections. Failure to do so could cause corrosion or freeze damage to heat exchanger water passage tubes. 4. Remove the anode plug and drain the heat exchanger. 80057 Heat exchanger Anode plug...
  • Page 90 MAINTENANCE SECTION 5 NOTE: In the following steps, it may be necessary to lower or bend the hoses to allow water to drain completely. 7. Disconnect the seawater inlet hose from the connector on the seawater pump hose and drain. 80064 Seawater inlet hose Connector...

  • Page 91: Cleaning The Seawater Strainer, If Equipped

    SECTION 5 MAINTENANCE 00000 – was Cleaning The Seawater Strainer, If Equipped 1. Visually inspect seawater strainer through glass top. CAUTION While cleaning the seawater strainer, seawater can flow into the engine or engine compartment causing damage to the engine or boat. Water inlet must be closed before cleaning the seawater strainer.

  • Page 92: Flushing The Seawater System

    MAINTENANCE SECTION 5 00000 new Flushing The Seawater System NOTE: The closed cooling section of the cooling system that contains coolant does not need to be flushed. Coolant is changed at specified intervals. Refer to Maintenance Schedules. Flushing the seawater system with fresh water is needed only for salty, brackish, mineral laden or polluted water applications to avoid silt or salt buildup.
  • Page 93 SECTION 5 MAINTENANCE 3. Using an appropriate adapter, connect the flushing hose from a water tap to the seawater inlet hose connected to the seawater pump inlet. 80060 Typical Adapter Flushing hose Water tap Seawater inlet hose 4. Partially open the water source to about 1/2 maximum. Do not use full water pressure. CAUTION Engine overheating can cause engine damage.

  • Page 94: Checking The Water Pickups

    MAINTENANCE SECTION 5 Checking The Water Pickups THOUGH THE HULL OR THROUGH THE TRANSOM PICKUPS 1. Ensure that the seawater pickup water inlet holes are clean and not obstructed. 70355 72640 Typical Through The Hull Pickup Typical Through The Transom Pickup Water inlet holes Battery General...

  • Page 95: Multiple Electronic Control Engine Battery Precautions

    SECTION 5 MAINTENANCE 00000 was CE335 Multiple Electronic Control Engine Battery Precautions SITUATION Alternators: Alternators are designed to charge a single battery that supplies the electrical power to the individual engine that the alternator is mounted on. Connect only one battery to one alternator.
  • Page 96 MAINTENANCE SECTION 5 NOTES: Page 88 CMD-4081877 / 90-865861040 MARCH 2004...

  • Page 97: Table Of Contents

    SECTION 6 STORAGE AND RECOMMISSIONING SECTION 6 - STORAGE AND RECOMMISSIONING Table of Contents Cold Weather (Freezing Temperature), Seasonal Storage Instructions ..Seasonal, And Extended Storage ..Extended Storage Instructions .

  • Page 98: Cold Weather (Freezing Temperature), Seasonal, And Extended Storage

    STORAGE AND RECOMMISSIONING SECTION 6 0084 w / CMD Cold Weather (Freezing Temperature), Seasonal, And Extended Storage IMPORTANT: Cummins MerCruiser Diesel strongly recommends that this service should be performed by an authorized Cummins MerCruiser Diesel dealer / distributor. Damage caused by freezing IS NOT covered by the Cummins MerCruiser Diesel Limited Warranty.

  • Page 99: Cold Weather (Freezing Temperature) Storage

    SECTION 6 STORAGE AND RECOMMISSIONING Cold Weather (Freezing Temperature) Storage 1. Read all precautions and perform all procedures found in Section 5 - Draining The Seawater System and drain the seawater section of the cooling system. CAUTION If boat is in the water, the seacock must remain closed until the engine is to be re-started to prevent water from flowing back into the cooling system, boat, or both.

  • Page 100: Seasonal Storage Instructions

    STORAGE AND RECOMMISSIONING SECTION 6 00000 was CD927 w / changes Seasonal Storage Instructions 1. Read all precautions and perform all procedures found in Preparing Your Power Package For Seasonal or Extended Storage. 2. Read all precautions and perform all procedures found in Section 5 - Draining The Seawater System and drain the seawater section of the cooling system.

  • Page 101: Extended Storage Instructions

    SECTION 6 STORAGE AND RECOMMISSIONING 7. Remove the temporary hose from the seawater pump. CAUTION If boat is in the water, seacock must remain closed until engine is to be re-started to prevent water from flowing back into cooling system, boat, or both. If the boat is not fitted with a seacock, the water inlet hose must remain disconnected and plugged to prevent water from flowing back into the cooling system, boat, or both.

  • Page 102: Recommissioning

    STORAGE AND RECOMMISSIONING SECTION 6 CD928 w / changes Recommissioning NOTICE Refer to Cold Weather, Seasonal Storage, And Extended Storage - Precautions, BEFORE proceeding. NOTE: Discharge of propylene glycol into the environment may be restricted by law. Contain and dispose of propylene glycol in accordance with Federal, State, and local laws and guidelines.
  • Page 103 SECTION 6 STORAGE AND RECOMMISSIONING 9. Perform all checks on Operation Chart in the Starting Procedure column found in Section 3 of the Operation, Maintenance and Warranty Manual provided with the product. CAUTION Overheating from insufficient cooling water will cause engine and drive system damage.
  • Page 104 STORAGE AND RECOMMISSIONING SECTION 6 NOTES: Page 96 CMD-4081877 / 90-865861040 MARCH 2004...

  • Page 105: Section 7 - Troubleshooting

    SECTION 7 TROUBLESHOOTING SECTION 7 - TROUBLESHOOTING Table of Contents Diagnosing Electronically Controlled Fuel Poor Performance ....System Problems ..... . Excessive Engine Temperature .

  • Page 106: Diagnosing Electronically Controlled Fuel System Problems

    TROUBLESHOOTING SECTION 7 0102 changed to CMD and EDI not EFI Diagnosing Electronically Controlled Fuel System Problems Your authorized Cummins MerCruiser Diesel dealer / distributor has the proper service tools for diagnosing problems on electronically controlled fuel systems. The Electronic Control Module (ECM) on these engines has the ability to detect some problems with the system when they occur, and store a Trouble Code in the ECM’s memory.

  • Page 107: Engine Will Not Start, Or Is Hard To Start

    TROUBLESHOOTING SECTION 7 Engine Will Not Start, Or Is Hard To Start Possible Cause Remedy Lanyard stop switch activated. Check lanyard stop switch. Improper starting procedure. Read starting procedure. Empty fuel tank or fuel shut off valve Fill tank or open valve. closed.

  • Page 108: Engine Runs Rough, Misses And/Or Backfires

    TROUBLESHOOTING SECTION 7 0105 w / changes – EDI and CMD Engine Runs Rough, Misses And/Or Backfires Possible Cause Remedy Throttle not operating properly. Check throttle linkages for binding or an obstruction. Idle speed too low. Check idle speed and adjust, if necessary. Clogged fuel or air filters.

  • Page 109: Excessive Engine Temperature

    TROUBLESHOOTING SECTION 7 0107.2 with CMD changes Excessive Engine Temperature Possible Cause Remedy Water inlet or seacock closed. Open. Drive belt loose or in poor condition. Replace or adjust belt. Seawater pickups or sea strainer Remove obstruction. obstructed. Faulty thermostat. Replace.

  • Page 110: Low Engine Oil Pressure

    TROUBLESHOOTING SECTION 7 0109 with CMD changes Low Engine Oil Pressure Possible Cause Remedy Faulty senders. Have system checked by an authorized Cummins MerCruiser Diesel dealer / distributor. Insufficient oil in crankcase. Check and add oil. Check and remove required amount of oil. Excessive oil in crankcase (causing it to Check for cause of excessive oil (improper become aerated).
  • Page 111 SECTION 8 CUSTOMER ASSISTANCE INFORMATION SECTION 8 - CUSTOMER ASSISTANCE INFORMATION Table of Contents Owner Service Assistance ... . . Muut kielet ......Local Repair Service .

  • Page 112: Section 8 - Customer Assistance Information

    CUSTOMER ASSISTANCE INFORMATION SECTION 8 CD944 w/ CMD changes Owner Service Assistance Local Repair Service Always return your Cummins MerCruiser Diesel (CMD) powered boat to your authorized dealer should the need for service arise. Only he has the factory trained mechanics, knowledge, special tools and equipment and the genuine Quicksilver parts and accessories* to properly service your engine should the need occur.

  • Page 113: Replacement Service Parts

    CUSTOMER ASSISTANCE INFORMATION SECTION 8 CE472 Replacement Service Parts WARNING Electrical, ignition and fuel system components on Cummins MerCruiser Diesel en- gines and drive systems are designed and manufactured to comply with U.S. Coast Guard Rules and Regulations to minimize risks of fire or explosion. Use of replacement electrical, ignition or fuel system components, which do not comply to these rules and regulations, could result in a fire or explosion hazard and should be avoided.

  • Page 114: Resolving A Problem

    CUSTOMER ASSISTANCE INFORMATION SECTION 8 CE545 Resolving A Problem Satisfaction with your Cummins MerCruiser Diesel product is very important to your dealer and to us. If you ever have a problem, question or concern about your power package, contact your authorized Cummins MerCruiser Diesel dealer / distributor. If additional assistance is required, take these steps: 1.

  • Page 115: Customer Service Literature

    W6250 West Pioneer Road P.O. Box 1939 Fond du Lac, WI 54935-1939 Outside the United States and Canada, contact the nearest Mercury Marine or Marine Power International Service Center for further information. When ordering be sure to: List your product, model, year and serial numbers.

  • Page 116: Andere Sprachen

    Para obtener un Manual de operación y mantenimiento en otro idioma, póngase en contacto con el centro de servicio más cercano de Mercury Marine o Marine Power International para recibir información. Con su conjunto motriz se entrega una lista de los números de pieza para los otros idiomas.

  • Page 117: Ordering Literature

    United States and Canada For information on additional literature that is available for your particular Cummins MerCruiser Diesel power package and how to order that literature contact your nearest Cummins MerCruiser Diesel dealer / distributor or contact: Mercury Marine Telephone Mail Mercury Marine Attn: Publications Department (920) 929–5110...

  • Page 118: Cmd-4081877 / 90-865861040 March

    CUSTOMER ASSISTANCE INFORMATION SECTION 8 00000 was CD851 75308 Page 110 CMD-4081877 / 90-865861040 MARCH 2004...

Table of Contents